Valve with shuttle for use in flow management systems

ABSTRACT

A valve with a shuttle for use in a flow management system is capable of bypassing a backflow.

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No.13/746,279 filed Jan. 21, 2013 which is a divisional patent applicationof U.S. patent application Ser. No. 12/766,141 filed Apr. 23, 2010, nowU.S. Pat. No. 8,545,190 and entitled VALVE WITH SHUTTLE FOR USE IN AFLOW MANAGEMENT SYSTEM.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a system for managing a fluid flow. Inparticular, the system includes a valve with a shuttle for managing afluid flow.

Discussion of the Related Art

Pumps and valves located in hard to reach places present maintenance andmaintenance downtime issues. Where pumps and valves are used to producea natural resource such as a hydrocarbon, downtime can result in lostproduction and increased expenses for workmen and materials.

In particular, downhole production strings including pumps and valvesfor lifting fluids such as particulate laden liquids and slurriespresent a maintenance problem. Here, both pumps and valves can losecapacity and in cases be rendered inoperative when conditions includingfluid conditions and fluid velocities fall outside an intended operatingrange. Such unintended operating conditions can foul, plug, and damageequipment.

The oil and gas industry is familiar with these production equipmentproblems and has in cases benefited from equipment designed to mitigateproduction process upsets. However, once this industry adopts aparticular equipment design, it is slow to consider improvements forreasons including familiarity with existing equipment and the riskassociated with using the untested equipment of market newcomers.

Production string bypass valves are one such example. Old designs arefamiliar and trusted to increase production process reliability. Despitea potential to further improve reliability using improved bypass valves,the industry chooses instead to maintain the status quo, buying the sametypes of bypass valves year after year.

Improvements in production string bypass valves are needed together witha willingness to adopt improved designs that increase production processreliability.

SUMMARY OF THE INVENTION

The present invention includes a valve with a shuttle and is intendedfor use in a flow management system.

In an embodiment, a valve body includes a spill port and a shuttle islocated in a chamber of the valve body. The shuttle has a through holeextending between a shuttle closure end and a shuttle spring end. Afirst seat and a first seat closure are located in the through hole.Second and third seats are located in the valve body chamber and secondand third seat closures are located on the shuttle closure end. A springis located substantially between the shuttle spring end and a fixturecoupled to the valve body. The valve is operable to pass a flow enteringthe through hole at the shuttle spring end and to spill a flow thatcloses the first seat closure. In some embodiments, the circumference ofthe second seat is greater than the circumference of the third seat andthe circumference of the shuttle spring end is more than two timesgreater than the circumference of the third seat.

In an embodiment, a valve body includes a spill port and a shuttlelocated in a chamber of the valve body. The shuttle has a through holeextending between a shuttle closure end and a shuttle spring end. Avalve center line is shared by the valve body and the shuttle. A firstseat is located on a first face of the shuttle and there is a first seatclosure. The first seat closure has a central bore for accepting arotatable shaft extending through the valve body and the first seatclosure is for translating along the rotatable shaft. A second seat islocated in the valve body chamber and a second seat closure is locatedon a second face of the shuttle. A spring is located substantiallybetween the shuttle spring end and a valve body support. The valve isoperable to pass a flow entering the through hole at the shuttle springend and to spill a flow that closes the first seat closure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described with reference to the accompanyingfigures. These figures, incorporated herein and forming part of thespecification, illustrate the invention and, together with thedescription, further serve to explain its principles enabling a personskilled in the relevant art to make and use the invention.

FIG. 1 is a schematic diagram of a valve in a flow management system inaccordance with the present invention.

FIG. 2 is a diagram of the flow management system of FIG. 1.

FIG. 3 is a cross-sectional view of a valve of the flow managementsystem of FIG. 1.

FIG. 4 is a cross-sectional view of a second valve of the flowmanagement system of FIG. 1.

FIG. 5 is a cross-sectional view of a seal of the flow management systemof FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The disclosure provided in the following pages describes examples ofsome embodiments of the invention. The designs, figures, and descriptionare non-limiting examples of certain embodiments of the invention. Forexample, other embodiments of the disclosed device may or may notinclude the features described herein. Moreover, disclosed advantagesand benefits may apply to only certain embodiments of the invention andshould not be used to limit the disclosed invention.

To the extent parts, components and functions of the described inventionexchange fluids, the associated interconnections and couplings may bedirect or indirect unless explicitly described as being limited to oneor the other. Notably, indirectly connected parts, components andfunctions may have interposed devices and/or functions known to personsof ordinary skill in the art.

FIG. 1 shows an embodiment of the invention 100 in the form of aschematic diagram. A bypass valve 108 is interconnected with a pump 104via a pump outlet 106. The pump includes a pump inlet 102 and the valveincludes a valve outlet 110 and a valve spill port 112. In variousembodiments, the inlets, outlets and ports are one or more of a fitting,flange, pipe, or similar fluid conveyance.

FIG. 2 shows a section of a typical downhole production string 200. Theproduction string includes the bypass valve 108 interposed between thepump 104 and an upper tubing string 204. In some embodiments, a casing208 surrounds one or more of the tubing string, valve, and pump. Here,an annulus 206 is formed between the tubing string and the casing. Aproduction flow is indicated by an arrow 102 while a backflow isindicated by an arrow 202. In various embodiments, the bypass valveserves to isolate backflows from one or more of the valve, portions ofthe valve, and the pump.

FIG. 3 shows a first bypass valve 300. A valve body 324 housescomponents including a valve shuttle 337 and a charge spring 312. Thevalve body has a central chamber 323.

The shuttle 337 includes an upper section 340 adjacent to a lowersection 341. In an embodiment, the central chamber includes a first bore344 for receiving the lower shuttle section and a second bore 346 forreceiving the upper shuttle section. In embodiments where the first andsecond bore diameters are different, a grease space 332 may be providedbetween the shuttle 337 and the valve body section 370 (as shown). Inother embodiments, the first and second bore diameters are substantiallythe same and there is no grease space.

Upper and lower seals 314, 330 are fitted circumferentially to the uppershuttle section and the lower shuttle section 340, 341. In anembodiment, the seals have a curved cross-section such as a circularcross-section (as shown). In another embodiment the seals have arectangular cross-section.

In some embodiments, one or more seals 314, 330 have a structure 500similar to that shown in FIG. 5. Here, a seal body 502 such as apolymeric body has inner and outer lip seals 506, 504 and substantiallyenvelops a charge O-ring 508 such as a silicon rubber ring.

In various embodiments, the seals 314, 330 are made from one or more ofa rubber, plastic, metal, or another suitable material known to personsof ordinary skill in the art. For example, seal materials includesilicone rubber, elastomers, thermoplastic elastomers, and metals thatare soft in comparison to the valve body 324, the selection depending,inter alia, on the valve application. In an embodiment, the seals aremade from ultra high molecular weight polyethylene.

The shuttle has a through-hole 356 including an upper through-holesection 342 and a lower through-hole section 352. Upper and lowerthrough-hole ports 362, 360 bound a flow path through the shuttle 337.In an embodiment, the upper through-hole cross-section is smaller thanthe lower through hole cross-section.

Located near the lower through-hole section is a first seat closure 354,a first seat 326, and a seat retainer 356. In an embodiment, the firstseat is about radially oriented with respect to the valve bodycenterline 301.

In an embodiment, the first seat closure 354 is a plug. In variousembodiments, the first seat closure is spherically shaped, conicallyshaped, elliptically shaped, or shaped in another manner known topersons of ordinary skill in the art. And, in an embodiment, the firstseat closure is substantially spherically shaped. The closure is movablewith respect to the shuttle 337 within a cage 328. When resting againstthe first seat 326, the first closure seals the lower through-hole port360. In an embodiment, a stabilizer near an upper end of the cage 351prevents the closure from blocking the passage comprising the upper andlower through-hole sections 342, 352 when the closure is near the upperend of the cage 390.

Located near an upper valve body section 350 is a second seat 318. In anembodiment, the second seat is about radially oriented with respect tothe valve body centerline 301.

A second seat closure 317 is located at an upper end of the shuttle 337.In an embodiment, the second seat closure is located on a peripheral,sloped face of the shuttle 319. In various embodiments, the second seatclosure is spherically shaped, conically shaped, elliptically shaped, orshaped in another manner known to persons of ordinary skill in the art.And, in an embodiment, the second seat closure is substantiallyfrustro-conically shaped. The closure is movable with the shuttle alonga line substantially parallel to a centerline of the valve body 301.

Located near an upper valve body section 350 is a third seat 368. In anembodiment, the third seat is about radially oriented with respect tothe valve body centerline 301. About radially arranged and locatedbetween the second and third seats 318, 368, are one or more spill ports316 extending between a valve body exterior 372 and the valve bodycentral chamber 323.

A third seat closure 367 is located at an upper end of the shuttle 337.In an embodiment, the third seat closure is located on a peripheral,sloped face of the shuttle 319. In various embodiments, the third seatclosure is spherically shaped, conically shaped, elliptically shaped, orshaped in another manner known to persons of ordinary skill in the art.And, in an embodiment, the second seat closure is substantiallyfrustro-conically shaped. The closure is moveable with the shuttle alonga line substantially parallel to a centerline of the valve body 301.

The second and third seat closures 317, 367 are formed to simultaneouslyclose the second and third seats 318, 368. When resting against thesecond and third seats 318, 368, the second closure establishes a flowpath between a variable volume valve chamber below the shuttle 362 andan upper valve chamber above the second seat 364 while the third closureblocks flow in the spill port 316. When moved away from the second seat,the second closure unblocks flow in the spill port.

Tending to bias the shuttle 337 upward is the charge spring 312. Invarious embodiments, the charge spring is about radially oriented withrespect to the valve body centerline 301 and is seated 384 on an annularfixture supported by the valve body 386. In various embodiments, thefixture is In an embodiment, an upper end of the spring 382 pressesagainst the shuttle.

In normal operation, forces on the shuttle determine the position of theshuttle.

-   -   a. The spring exerts an upward force on the shuttle.    -   b. The shuttle exerts a downward weight related force on the        spring.    -   c. A lower chamber pressure P1 is applied to a lower fluid        exposed area of the shuttle A1 resulting in an upward force on        the shuttle.    -   d. An upper chamber pressure P2 is applied to an upper fluid        exposed area of the shuttle A2 resulting in a downward force on        the shuttle        The equilibrium position of the shuttle in the valve body 324 is        determined by the forces acting on the shuttle.

For example, when the pump 104 is lifting fluid through the valve 300,the spring constant k of the charge spring 312, the area A1, and thearea A2 are selected to cause a net upward force on the shuttle tendingto move the shuttle to its uppermost position, sealing the spill ports316. At the same time, the rising fluid lifts the first closure awayfrom its seat. These actions establish a flow path through the shuttle.In an embodiment, A1 is greater than A2. And, in an embodiment, A1 isabout three times larger than A2.

When fluid lifting stops or falls below a threshold value, the net forceon the shuttle tends to move the shuttle away from its uppermostposition. At the same time, insufficient rising fluid causes the firstclosure 354 to come to rest against the first seat 326. These actionsunblock the spill ports 316 and establish a fluid flow path from theupper chamber 364 to the spill port(s) 316 while blocking the flow paththrough the shuttle.

From the above, it can be seen insufficient fluid flow, no fluid flow,or reverse fluid flow cause the valve 300 and pump 104 to be removedfrom the fluid circuit and/or isolated from the fluid column above theshuttle 337. A benefit of this isolation is protection of the valve andpump. One protection afforded is protection from solids, normally risingwith the fluid but now moving toward the valve and pump, that mightotherwise foul or block one or both of these components. Blocking theshuttle flow path and opening the spill ports 316 removes these solidsoutside the tubing string 204.

FIG. 4 shows a second bypass valve 400. A valve body 424 housescomponents including a valve shuttle 437, a valve closure 483, and acharge spring 412. The valve body has a central chamber 423 and arotatable shaft 482 passes through the central chamber. The shuttleincludes an upper section 440 adjacent to a lower section 441.

Upper and lower seals 414, 430 are fitted circumferentially to the uppershuttle section and the lower shuttle section 440, 441. As seen, theseals bear against an inside wall of the valve 4111. In one embodiment,the seals have a curved cross-section such as a circular cross-section.In another embodiment, the seals have a rectangular cross-section (asshown).

In some embodiments, one or more seals 414, 430 have a structure 500similar to that shown in FIG. 5. Here, a seal body 502 such as apolymeric body has inner and outer lip seals 506, 504 and substantiallyenvelops a charge O-ring 508 such as a silicon rubber ring.

And, in various embodiments, the seals 414, 430 are made from one ormore of a rubber, plastic, metal, or another suitable material known topersons of ordinary skill in the art. For example, seal materialsinclude silicone rubber, elastomers, thermoplastic elastomers, andmetals that are soft in comparison to the valve body 424, the selectiondepending, inter alia, on the valve application. In an embodiment, theseals are made from ultra high molecular weight polyethylene.

The shuttle and valve closure 437, 483 have through-holes 456, 457 andthe rotatable shaft 482 passes through these through-holes. A first faceof the shuttle in the form of a first seat 468 is for sealing against aface of the valve closure 467. In an embodiment, the first seat is nearan upper end of the shuttle 440 and the valve closure sealing face isnear a lower end of the valve closure 488. In some embodiments, thefirst valve seat is about radially oriented with respect to the valvebody centerline 401. In various embodiments, the shuttle sealing face isintegral with or coupled to the shuttle. And, in various embodiments,the valve closure sealing face is integral with or coupled to the valveclosure.

A second face of the shuttle 417 is for sealing against a face of thevalve body and is in the form of a second seat 418. In an embodiment,the second seat is near an upper section of the valve body 450 and thesecond face of the shuttle is near an upper end of the shuttle 440. Insome embodiments, the second valve seat is about radially oriented withrespect to the valve body centerline 401. In various embodiments, theshuttle sealing face is integral with or coupled to the shuttle. And, invarious embodiments, the second seat is integral with or coupled to thevalve body 424.

About radially arranged and located between upper and mid valve bodysections 450, 470 are one or more spill ports 416. Each spill portextends between inner and outer walls of the valve body 471, 472.

Tending to bias the shuttle 437 upward is the charge spring 412. Invarious embodiments, the charge spring is about radially oriented withrespect to the valve body centerline 401 and is seated at a lower end413 in a slot 496 formed in the valve body center section 470. In anembodiment, an upper end of the spring 415 presses against the shuttle.

Operation of the second bypass valve 400 includes turning of the shaft482 which is normally the means of operating the pump 104. In normaloperation, forces on the shuttle 437 and valve closure 483 determinetheir position. When the pump 104 is lifting fluid within the tubing andwithin a designed flow-rate range 490, the shuttle rises to itsuppermost position 494 under the influence of the charging spring 412and the rising fluid lifts the valve closure free of the shuttle 484.Notably, in its uppermost position, the shuttle blocks the spill ports416 when shuttle sealing face 417 seals with the first seat 418.

When the pump 104 ceases to lift fluid at a sufficient rate, as withback-flow 491, the valve closure contacts the shuttle 486 and the valveclosure sealing face 467 seals with the second seat 468. Further, if theforce resulting from the pressure above the first seat P22 overcomes theforce of the charging spring 412 and the force resulting from thepressure below the valve closure 483, the shuttle is pushed down 496 andthe spill port(s) 416 are unblocked allowing fluid in the tubing abovethe valve to spill outside the valve 400, for example into the annularspace between the tubing and the casing 206.

From the above, it can be seen insufficient fluid flow, no fluid flow,or reverse fluid flow cause the valve 400 and pump 104 to be removedfrom the fluid circuit and/or isolated from the fluid column above theshuttle 437. A benefit of this isolation is protection of the valve andpump. One protection afforded is protection from solids, normally risingwith the fluid but now moving toward the valve and pump, that mightotherwise foul or block one or both of these components. Blocking theflow path around the shuttle and opening the spill ports 416 removesthese solids outside the tubing string 204.

The present invention has been disclosed in the form of exemplaryembodiments; however, it should not be limited to these embodiments.Rather, the present invention should be limited only by the claims whichfollow where the terms of the claims are given the meaning a person ofordinary skill in the art would find them to have.

What is claimed is:
 1. A method of protecting a pump comprising thesteps of: lifting fluid from a hydrocarbon reservoir with the pump;providing a valve downstream of the pump, the valve including a shuttleand a valve body; providing a shuttle through hole, the through holeincluding a shuttle chamber interconnecting a first shuttle port and ashuttle passage, the shuttle passage leading to a second shuttle port;inserting a spherical closure in the shuttle chamber, the sphericalclosure free to move within the chamber under the influence of a fluidflow passing through the chamber; movably inserting the shuttle in avalve body chamber and a positioning a spring between the shuttle and avalve body fixture; controlling operation of a spill port with a shuttlenose that incorporates the second shuttle port, the spring tending toclose the spill port; and, closing the spill port when a) flow carriesthe spherical closure toward the second shuttle port but does not blockthe second shuttle port and b) the spring gets longer; wherein the pumpis protected by opening the spill port when a) flow carries thespherical closure to block the first shuttle port and b) the spring getsshorter.
 2. The method of claim 1 wherein a shuttle perimeter is forsealing against a valve body interior and for forming a movable seal. 3.The method of claim 2 wherein a cage limits motion of the sphericalclosure, the cage including a stabilizer that prevents the sphericalclosure from blocking flow moving from the shuttle chamber to theshuttle passage.
 4. The method of claim 2 wherein a spilled flow entersan annulus bounded by a casing.
 5. The method of claim 2 wherein thespill port empties into an annulus between a string casing and a stringtubing such that a spilled flow replenishes the hydrocarbon reservoir.6. The method of claim 2 wherein the spring is in a space between afirst port end of the shuttle and an end of the valve.
 7. The method ofclaim 2 wherein the second shuttle port is in a conical shuttle closurefor mating with a conical valve body seat.
 8. The method of claim 2wherein the shuttle has a first outer diameter at the shuttle chamberand a second outer diameter at the shuttle passage, the first diameterbeing greater than the second diameter.
 9. The method of claim 8 whereinthe shuttle has a first inner diameter at the shuttle chamber and asecond inner diameter at the shuttle passage, the first diameter beinggreater than the second diameter.
 10. The method of claim 2 furtherincluding the step of: forcing the shuttle to move in a direction thatopens the spill port when spring force and pump pressure force on ashuttle end are overcome by a fluid head force on an opposite shuttleend.